FUNDAMENTALS OF DESIGN AND MANUFACTURING. Time: Three hours. Maximum marks: Answer FIVE questions, taking ANY TWO from Group A. Fundamentals of Design & Manufacturing. PDF Files, Video Files. Design Introduction, Link to video file 1. Life Cycle, Link to Video file 2. Link to pdf file 3, Link to. Amie Fundamentals of Design and Manufacturing Design - Download as PDF File .pdf), Text File .txt) or read online.
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Fundamentals of Design and Manufacturing - Free download as Word Doc .doc), PDF File .pdf), Text File .txt) or read online for free. the fundamentals of a process, they can easily apply it A. H. Slocum, Precision Machine Design, Society of Manufacturing Engineers, FUNDAMENTALS OF DESIGN AND MANUFACTURING. Time: Three hours. Maximum Marks: Answer FIVE questions, taking ANY TWO trom Group A.
Chapter 8 addresses standards for the use of inherently diverse discrete products. Chapter 9 provides a procedure for discrete product design and manufacture with consideration to ergonomics.
Several standards-developing organizations are surveyed to identify appropriate standards to design and manufacture discrete products with ergonomic constraints. Chapter 10 presents a review of support standards for core design and manufacturing activities. This chapter encompasses standards related to computer interfacing, communication, software development, and ebusiness procedures.
Chapter 11 presents a case study that addresses the multidisciplinary mechatronics application. It provides terms and conditions for digital interfacing and control software development for a milling machine by use of appropriate standards.
The subject area addressed in this book covers a very large domain. To keep the book to a manageable size, several common concepts, addressed sufficiently in other books, have been presented in condensed form, so that the core topic, the use of standards for design and manufacturing of discrete products, remains the focus.
For other topics, related references are available in the bibliographies. In most cases, the Web site of a related organization is provided. In some cases, acronyms are used to identify the organization. Such acronyms and search words used in the surveys can easily be resolved at a search engine on the World Wide Web. The search word or the wild card selection affects the output from an online or a CD-based search for standards. The information derived from Web sites of standards organizations is copyrighted by those organizations and was correct at the time of browsing.
Most of the organizations surveyed as presented in Chapter 2 develop procedures, codes, and standards. The major emphasis of this book is on standards; however, other organizations are listed because of their direct relevance to the design and manufacturing of discrete products. One of the major objectives of this book is to introduce the potential of utilizing the standards in engineering design and manufacturing of discrete products to acquire the benefits of standardization.
The Appendix at the end of the book provides basic information regarding online catalogs related to standard machine elements and standard control elements, digital libraries for standards, and the Web sites related to standards. Comprehensive references are also provided as bibliographies at the end of each chapter to help readers with the wealth of material available in related fields. Ghulam Haider Mughal, Mr. Syed Mojiz Raza, and Mr.
John Corrigan for their help in designing and producing this book.
We also acknowledge the support of the students Mr. Sultan Al-Thanayan and Mr. Haroon Naseer. The patience of our family members is deeply appreciated. The authors and the publisher are not responsible for any injury, loss of life, or financial loss arising from use of material in this book.
The process of guided development began the day primitive humans started using logic to overcome their basic problems. Understanding arose, default by nature or established through experience: that night with or without stars follows day; that clouds may bring rain from which some sort of protection is needed; and that something is eaten, whether vegetation or animal. Perhaps lightning started the first fires, and humans learned to make certain types a spark with stones by rubbing them together.
The establishment of that fact, whether planned or accidental, made primitive humans aware that fire makes vegetation and meat tender and makes them taste different—perhaps better. The need existed, and observation and experimentation were the only tools.
Many superstitious factors such as trust in magic and misunderstanding of cause and effect have discouraged human beings from overcoming ignorance. The more influential factor, from primitive to modern times, has remained the need to safeguard oneself from predators, to fulfill the basic needs of life, or to dominate a piece of land or group of people. The need has led to progress that has continued from the Stone Age, to the Bronze Age, to the Iron Age, and now to the modern world.
Engineering and science have remained exercises in observation and experimentation, over a very long period of time, to satisfy the need. In the process, humans have established laws to further the progress.
The need, in all the defined or undefined areas of engineering and sciences, does not restrict itself to any level of development; it forges ahead, through old and new analytical, numerical, and experimental procedures. The need is still the prime factor in the production of art, science, engineering, and technology. Scientists and engineers still venture into the unknown to find longlasting solutions.
Some of the inventions that have made lasting marks on the history of humankind are presented in Table 1. Microscope Holland A. Comments Engineering material clay Mechanism Mechanism Inference engine Inference engine Time Publishing Observation of planetary movement Observation of microbes Transportation Communication Transportation Communication Transportation Production Medicine Weapons Inference engine Communication Space travel With the evolution of multidisciplinary engineering design and manufacturing from the Industrial Revolution to today, the need to standardize procedures to develop discrete products has increased manifold.
This need encompasses areas such as methodology associated with design and manufacturing functions, use of materials, shape and size of the envisaged product, geometry data transfer to all other functions in the computer-integrated manufacturing CIM environment, and waste disposal.
Although standardization is promoted for most tasks in engineering design and manufacturing, certain tasks cannot be standardized or may not be accessible to the general engineering community. At the same time, standardization may not be seen as a developmentrestricting factor because of the evaluation procedure associated with the standardization. A discrete component is an object that can be uniquely identified in an assembly or a mechanism generally called a product.
In each case, these discrete components must be properly selected and precisely arranged in a predetermined pattern to result in a functioning unit an assembly. An exploded view of a simplified revolute robot that shows various components, top view of the mechanism, and the solid model are shown in Figure 1.
This robot constitutes a basic example of discrete components, assembly, and mechanism. Detailed design; design for manufacture, assembly, shipping, maintenance, use, and recyclability. Design checks for clarity, simplicity, modularity and safety. Standardization and size ranges. Reliability and robust design. Design organisation and communication,. Concept of manufacturing; classification of manufacturing processes.
Fundamentals of casting. Basic understanding of commonly used casting processes sand casting, investment casting and permanent mould casting processes. Fundamentals of metal forming; hot and cold working; basic understanding of primary metal forming processes rolling, forging, extrusion and drawing processes, punching and blanking.
Group B Fundamentals of metal cutting; tool-work interaction for production of machined surfaces. Classification of machining processes.
Basic machining operations turning, shaping, planning, drilling and milling processes. Explain their formation. What is chip breaker? What Specifications are needed to purchase this machine.
Under what conditions the use of this machine is recommended? State its applications. What is Electrolyte and explain its role? Explain oxy- acetylene gas welding procedure. Justify the statement. Ph 11 c Discuss the application of the information technology in the integration of business and technological aspects.
Describe the role of sensors in controllers. B Select the correct answer out of the alternative choices Of the following: 1x8 i Cores are used to a make desired recess in castings b strengthen moulding sand c support loose pieces d remove pattern easily ii Shell moulding process requires a wooden patterns b sand patterns c plastic patterns d metal patterns iii In arc welding, eyes need to be protected against a intense glare b infra-red rays only c ultraviolet rays only d both infra-red and ultraviolet rays iv The gases used in tungsten inert gas welding are a hydrogen and oxygen b argon and helium c argon and neon d helium and neon.
All parts of a question a,b, etc should be answered at one place. Answers should be brief and to-the-point and be supplemented with neat sketches. Unnecessary long answer may result in loss of marks. Any missing or wrong data may be assumed suitably giving proper justification.
Figures on the right —hand side margin indicates full marks. Discuss with a suitable examples. How it will help in achieving economic manufacturing? Distinguish between need analysis and need statement.
Explain briefly. What are the different processes that will represent the area of manufacturing? Find out the shear plane angle and also the magnitude of the shear strain.
When do you recommend the use of the machine? Explain the alternative arrangement of spindle and table of surface grinder along with their relative motion with the help of suitable sketches. Describe the significance in manufacturing. Give examples for each case.
How does it help in manufacturing? Describe briefly a database model for manufacturing. Describe its special features and important elements. Ph 13 8 a what do you understand by group technology? How the parts are segregated in broad groups? Write only the letter code without repeating the text of the question.
Figures on the right-hand side margin indicate full marks.
How is it useful for the design process? Classify the various manufacturing processes. Explain the role of 'structure' in a grinding wheel. Discuss the advantages of using group technology in a manufacturing set-up.
How is it useful in design and manufacturing? Also, describe its types 10 b What is a robot? How are robots specified? A Fill in the blanks: 1 x 10 i Grinding wheel is a cutting tool. Ph 15 vi In hot working, metals are heated the recrystallization temperature. B Answer the following in brief: 2x5 i Name five commonly used unconventional machining processes.
Forwarded By Jyothis Academy, Kottayam. Phone Mob Email jyothisacademy gmail. Explain why stages are repeated several time. How will it help in achieving economic manufacturing 6M c Differentiate between standardization and specification giving appropriate examples.
Also, explain how design is organized and communicated 10M b Compare the reliabilities of system with components in series vs. In a system , there are 10 com ponents in series, each with a reliability factor of 0. W hat is the overall reliabil ity of the system? If each of the10 components is in parallel and has individual f actor of 0. List four castings?
Nam e the operations which can be performed on a lathe machine 8 mark b Differentiate between the shaper and planner. W hat precautions sh ould be taken durin g welding? Assum e approach and over-travel distance as half of the diameter of the cutter and depth of 4. Discuss with examples.
What are the benefits of GT over the conventional setup? How can it be realized in practice? Why are these processes necessary? Explain 6 M c Explain briefly information technology and its elements. How is it superior to m anual process planning?
Discuss the same with a suitable example. IIIustrate with the help of an example 10 2. Di scuss various m aterial used for m aking pattern. Compare the reliability system with component in series parallel.
Discuss advantages of cold working over hot working. Explain rolling process in brief. What are the disadvantages of orthogonal cutting over oblique cutting? How it happens? List main components of a lathe machine. What are various factors considered in selection of proper grinding wheel? Discuss different stages involved for adopting a plan for GT. How is it superior to m anual process?
Group A 1 a Consider the example of product, and briefly explain various steps to be followed to design this product. Explain various stages of product life-cycle with a suitable example. Outline some typical applications of the process. Give relative advantages of each 5 4 a Describe the permanent mould casting process. Give any two application of this process of casting. What factors determine the drawing ratio?
Give advantages and limitations of three high rolling.